Safety/Pressure Relief Valve Sizing Evaluation

The methods described in the Pressure Protection Design Guide (WSRC-M-DP-G-0006), the Anderson
Greenwood Crosby (2001) manual (Error: Reference source not found), API 520, Pt. 1 and the Kunkle
Manual (2011), were used to calculate the pressure relief flow area and valve orifice size. The basic
equations used are:
1

Sonic flow for vapors and gases (but not steam) through a pressure safety valve (PSV) [Anderson
Greenwood Crosby (2001) Manual, pg. 29, Eqn. 1 or similar equation from the Pressure
Protection Design Guide (WSRC-M-DP-G-0006), pg. 42, eqns. VII-1 or API-520]. Also, other
forms are available when using mass flow or specific gravity:

A=

V MTZ
6.32 C K d P1 K b K c

A=

V MTZ
6.32 CK P1 K b

A=

V MTZ
6.32 C K d P1

WSRC-M-DP-G-0006), pg. 42, eqns. VII-1 or API-520, Pt.1, eqn. 3.3

Crosby (2001) Manual, pg. 29, Eqn. 1

Kunkle (2001) Manual, pg. 15

where,
A
V
M
T
Z
C

=
=
=
=
=
=

Valve orifice area (square inches);

Flow capacity [standard cubic feet per minute (scfm)];
Molecular weight of the flowing media (lb/lb mole);
Inlet temperature, absolute (F + 460);
Compressibility factor, determined from a real gas equation-of-state (dimensionless);
Gas constant, based on ratio of specific heats at standard conditions (dimensionless);

= ASME Coefficient of discharge (dimensionless), K = 0.9*K d or from the National Board

of Boiler and Pressure Vessel Inspectors, NB-18 Pressure Relief Device Certification,
URL: http://www.nationalboard.org/Index.aspx?pageID=64), Note, use K for ASME
applications or Kd for non-ASME applications (the ASME requires a 10% reduction in
the discharge coefficient for conservatism);

Kd = Effective coefficient of discharge or valve coefficient (dimensionless), equal to 0.975 for

preliminary sizing, or 0.62 for a rupture disk alone, or a value from the valve
manufacturer [API-520, Pt.1, pg 42];
Kb =
Kc

Capacity correction factor because of back pressure (dimensionless), value determined

from the valve manufacturer or from API-520, Pt.1, Figure 30;
= Combination correction factor for installations with a rupture disk upstream of a rupture
disk (dimensionless), equal to 1.0 with no rupture disk otherwise, 0.9 with a rupture disk
[API-520, Pt. 1, pg. 42] or specific data from the National Board of Boiler and Pressure
Vessel Inspectors, NB-18 Pressure Relief Device Certification,;

P1 =

Inlet pressure [pounds per square inch absolute (psia)] during flow conditions [set
pressure (psig) inlet pressure drop (psig) + overpressure (psig) + local atmospheric
pressure (psia)]; and

The value of C can be calculated by the following equation [Anderson Greenwood Crosby (2001)
Manual, Figure 5-3 or API-520, Pt. 1, Figure 32]:

C=520 k

2
k +1

k+1
k1

where,
k = Cp / Cv = 1.4 for nitrogen or air, 1.67 for Argon or 1.63 for P-10 gas and
Note:
C = 356 for nitrogen or air, 378 for Argon or 375 for P-10 gas.
The value of P1 is determined as follows;

P1=Pset + PPloss + P atm

where,
Pset = set pressure (psig), specified trip pressure of the PSV/PRV,
Pover = overpressure (psig), 10% of Pset or 3 psi (whichever is greater),
Ploss = inlet pressure drop (psig), (determined by pressure loss calculations) and
Patm = local atmospheric pressure (psia).
To determine if the flow is sonic or subsonic, the following equation is used (API-520, Pt.1, Eqn.
3.1):

P2
2
=
P1 k +1

( )

k
k1

and,
P2/P1 = 0.528 for k = 1.4 (air, nitrogen), 0.487 for k = 1.67 (Argon) or 0.492 for k = 1.63 (P-10
gas).
where,
P2 = Pressure downstream of the valve (psia), usually (but not always) local atmospheric
pressure.
As an example, for P-10 gas, if P2/P1 is less than or equal to 0.492, then the flow velocity is
sonic or choked or critical flow, if the pressure ratio is greater than 0.492 then the flow is
subsonic or sub-critical.
1.

Subsonic flow for vapors and gases (but not steam) through a pressure safety valve (PSV)
[Anderson Greenwood Crosby (2001) Manual, pg 35, Eqn. 6 or similar equation from the
Pressure Protection Design Guide (WSRC-M-DP-G-0006), pg. 42, eqns. VII-2. Note: there is a
typo in the Crosby Manual, but has been corrected in the equation below.] Also, other forms are
available when using mass flow or specific gravity:

A=

V
ZTM
4645.2 F2 K d K c P 1(P1 P2)

WSRC-M-DP-G-0006, pg. 42, eqn VII-2 or API-520 Pt.1,

eqn 3.6.

A=

V MTZ
4645 K vc P1 F s

A=

V
4645.2 F2 K d

Crosby Manual, pg 35, Eqn. 6

ZTM
P1 ( P1P2 )

Kunkle Manual (2011), pg 15.

where,
A
V
M
T
Z
F2
Fs
P1

=
=
=
=
=
=
=
=

P2 =
K

Valve orifice area (square inches);

Flow capacity (scfm), denoted at Qreq in WSRC-M-DP-G-0006;
Molecular weight of the flowing media;
Inlet temperature, absolute (F + 460);
Compressibility factor (determined from a real gas equation-of-state);
Coefficient, based on ratio of specific heats and valve pressure drop ratio;
Coefficient, based on ratio of specific heats and valve pressure drop ratio;
Inlet pressure (psia) during flow conditions [set pressure (psig) inlet pressure drop
(psig) + overpressure (psig) + local atmospheric pressure (psia)];
Pressure downstream of the valve (psia), usually (but not always) local atmospheric
pressure;

= ASME Coefficient of discharge, K = 0.9*Kd or from the National Board of Boiler and
Pressure Vessel Inspectors, NB-18 Pressure Relief Device Certification, URL:
http://www.nationalboard.org/Index.aspx?pageID=64), Note, use K for ASME
applications or Kd for non-ASME applications;

Kd = Effective coefficient of discharge or valve coefficient, equal to 0.975 for preliminary

sizing, or 0.62 for a rupture disk alone, or a value from the valve manufacturer.
Kc = Combination correction factor for installations with a rupture disk upstream of a rupture
disk, equal to 1.0 with no rupture disk otherwise, 0.9 with a rupture disk.
Kvc =

Coefficient of discharge or valve coefficient for subsonic flow [Anderson Greenwood

Crosby (2001) Manual, pg 37, Fig. 5-9 (for series 9300 valves)]. Also the following
equation can be used for Series 9300 Crosby valves (There is another Typo in the Crosby
manual that has been corrected below):

P
K vc=0.65 2
P1

0.349

( )

or as experimentally determined by the valve manufacturer

The value of Fs can be calculated by the following equation from the Anderson Greenwood
Crosby (2001) Manual, pg. 37, Eqn. 8.

k
F s=
( r ) k ( r )
k1

k +1
k

The value of F2 can be calculated by the following equation from the WSRC-M-DP-G-0006
report, Eqn. V-3 or API-520-Pt.1, pg 45 or the Kunkle Manual (2011), pg 15.

F2 =

( k1k )( r ) (
2
k

k1
k

1( r )
1r

And;
r

Ratio of back pressure to upstream pressure (P2/P1).

Note: The use of Crosby method vs. the WSRC-M-DP-G-0006 method will produce the same
results as the two equations are functionally equivalent.
2.

Incompressible flow for liquids through a pressure relief/safety valve (PRV/PSV) [Anderson
Greenwood Crosby (2001) Manual, pg 38, Eqn. 9, from the Pressure Protection Design Guide
(WSRC-M-DP-G-0006), pg. 42, Eqn. VII-3 or API-520, Pt.1, Eqn 3.9]:

A=

3.

Q G
38 K d K w K c K v P1P2

Incompressible flow for liquids through a pressure relief/safety valve (PRV/PSV), for ASME
Section VIII, 15 psig and above per the Kunkle Manual (2011), pg. 15:

2
1.1 P1P

38 K d
Q G
A=

4.

Incompressible flow for liquids through a pressure relief/safety valve (PRV/PSV), for NonASME Section VIII, per the Kunkle Manual (2011), pg. 15:

2
1.25 P 1P

38 K d
Q G
A=

Note, the Kunkle Manual, pg. 25, specifies correction factors, Kv and Kw, to be used to correct
the determined flow area, A. Therefore, the Kunkle manual method is the same as the other
methods by using these additional correction factors. In addition, the Kunkle manual method has
an additional correction factor of (1.1) 1/2 for ASME Code valves and (1.25)1/2 for non code valves.
where,
A =

Valve orifice area (square inches);

Q =

Flow rate (US gpm);

G =

Specific gravity of liquid at flowing temperature referred to water = 1.00 at 70F;

= ASME Coefficient of discharge, K = 0.9Kd or from the National Board of Boiler and
Pressure Vessel Inspectors, NB-18 Pressure Relief Device Certification, URL:
http://www.nationalboard.org/Index.aspx?pageID=64), Note, use K for ASME
applications or Kd for non-ASME applications;

Kc = Combination correction factor for installations with a rupture disk upstream of a rupture
disk, equal to 1.0 with no rupture disk otherwise, 0.9 with a rupture disk [API 520, Pt.1,
pg. 52].
Kd =

Coefficient of discharge on liquid [provided by the valve manufacturer, e.g. K = 0.869 for
Crosby HL safety valve, 0.65 for preliminary sizing (without a rupture disk) or 0.62 (with
a rupture disk is series with the PRV)];

Kv =

Viscosity correction factor, [determined from Figure 5-12 of Anderson Greenwood

Crosby (2001) Manual, pg 39, API-520, Pt.1 or Kunkle Manual (2011), pg.25]. For
turbulent flow, Kv is approximately 1.0;

Kw =

Back pressure correction factor for direct spring operated valves due to reduced lift (all
other valves Kw = 1.00), [determined from Figure 5-11 of Anderson Greenwood Crosby
(2001) Manual, pg 39, or API-520, Pt.1, Figure 31]. Kw equals 1.00 for a % back
pressure of 0 to 20%. Note, The Kunkle Manual does not define this correction factor;

P1 =

Inlet pressure (psia) during flow conditions [set pressure (psig) inlet pressure drop
(psig) + overpressure (psig) + local atmospheric pressure (psia)]; and,

P2 =

Pressure downstream of the valve (psia), usually (but not always) local atmospheric
pressure;

Kv can be determined from the Pressure Protection Design Guide (WSRC-M-DP-G-0006), pg. 30,
eqns. V-7 and V-8 or API-520, Pt.1, pg 52:

K v = 0.9935+

2.878 342.75
+
0.5
1.5
ori
ori

1.0

Where (API-520, Pt.1, Eqns 3.10 or 3.11):

ori =

2800GQ
A0.5
ori

, or

ori =

12,700Q
UA 0.5
ori

, and

Aori = the valve orifice flow area;

U =

kinematic viscosity of the fluid, SSU;

= dynamic or absolute viscosity of the fluid, cP;

P1 =

Inlet pressure (psia) during flow conditions [set pressure (psig) inlet pressure drop
(psig) + overpressure (psig) + local atmospheric pressure (psia)]; and,

P2 =

Pressure downstream of the valve (psia), usually (but not always) local atmospheric
pressure;

Vacuum breaker sizing

See item 1 above, subsonic flow for vapors and gases (but not steam) through a pressure safety
valve (PSV) [Anderson Greenwood Crosby (2001) Manual, pg 35, Eqn. 6 or similar equation

from the Pressure Protection Design Guide (WSRC-M-DP-G-0006), pg. 42, eqns. VII-2 or API520, Pt.1.]
2

Sonic flow for vapors and gases through a pressure control valve (PCV) (WSRC-M-DP-G-0006,
Eqn. III-1):

Qreq =16.204 P1 C v

2k
2 k1
k +1
G gT 1

( )

And, for converting scfm-gas specie to scfm air equivalent (WSRC-M-DP-G-0006, Eqn. V-1)
(simplified version for 1.1* Operating pressure is utilized):

Qa=2.9 Qs

T 1 g ( s) Z s M w(s )
Cs Kb

where,
Qreq =

Flow capacity [standard cubic feet per minute (scfm) for flowing gas];

Qa

Flow capacity [standard cubic feet per minute (scfm) equivalent for air];

Cs

Coefficient for flow gas determined from an expression of the gas k value;

Cv

Wide open valve flow coefficient (value reported by the manufacturer);

Gg

Specific gravity of flowing gas relative to air, both at standard conditions

Gas constant, ratio of specific heats, Cp/Cv of the flowing gas;

Kb

Capacity correction factor because of back pressure, usual value is = 1.0;

Mw(s) =

Molecular weight of the flowing gas;

P1

Inlet pressure [pounds per square inch absolute (psia)] during flow conditions;

T1g(s) =

Inlet temperature, absolute R (F + 460); and

Zs

Compressibility factor at inlet conditions (determined from a real gas equation-of-state).

The value of Cs can be calculated by the following equation [Anderson Greenwood Crosby
(2001) Manual, Fig. 5-3]:

C s=520 k
5.

2
k +1

k +1
k1

Subsonic flow for vapors and gases through a pressure control valve (PCV) (WSRC-M-DP-G-0006,
Eqn. III-1):

Qreq =16.204 C v

P 21P22
Gg T 1

And, for converting scfm-gas specie to scfm air equivalent (WSRC-M-DP-G-0006, Eqn. V-2)
(simplified version for when 1.1* Operating pressure is utilized):

Qa=Q s F 2(a)

T 1 g ( s) Z s M w(s)
122.8 F 2(s)

References:
1

API Standard 520, Sizing, Selection, & Installation of Pressure Relieving Devices, American
Petroleum Institute, Washington, D.C.

API Standard 2000, Venting Atmospheric and Low-Pressure Storage Tanks, American Petroleum
Institute, Washington, D.C.

Anderson Greenwood Crosby, Technical Seminar Manual, Tyco Valves & Controls Corp.,
Houston, Texas.

KUKMC-0398-US-1112 (Kunkle Valve Co.), Technical Reference for Safety and Relief Products,
Tyco Valves & Controls Corp., Houston, Texas.